Siemens SINAMICS GM150 User manual

www.siemens.com/drives
Medium-Voltage Drive
SINAMICS GM150
Type 6SL3815-2LN41-4AA2
Operating Instructions
Installation Instructions
Edition 04/2017

20.04.2017 13:25
V27.00

Medium-Voltage Drive
SINAMICS GM150
Type 6SL3815-2LN41-4AA2
Operating Instructions
Installation Instructions
Edition 04/2017
Introduction 1
Safety instructions 2
Description 3
Preparations for use 4
Installation 5
Electrical connection 6
Start-up 7
Operation 8
Maintenance 9
Spare parts 10
Disposal 11
Service & Support A
Technical data and drawings B
Checklists and forms C

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: MUSTER_Diodestack
Ⓟ 04/2017 Subject to change
Copyright © Siemens AG 2006, -, 2017.
All rights reserved

Table of contents
1 Introduction.................................................................................................................................................17
1.1 About these instructions.........................................................................................................17
2 Safety instructions......................................................................................................................................19
2.1 Warning symbol on the device...............................................................................................19
2.2 Qualified personnel................................................................................................................19
2.3 The five safety rules...............................................................................................................19
2.4 Safe handling.........................................................................................................................20
2.5 Electromagnetic fields in electrical power engineering installations ......................................23
2.6 Components that can be destroyed by electrostatic discharge (ESD)...................................24
2.7 Information for nominated persons in control of an electrical installation...............................25
2.7.1 Proper usage..........................................................................................................................25
2.7.2 Security information...............................................................................................................26
2.7.3 Grounding concept.................................................................................................................27
2.7.4 Installation site safety.............................................................................................................27
2.7.5 Measures for operator protection in electromagnetic fields...................................................28
2.8 Residual risks.........................................................................................................................28
3 Description..................................................................................................................................................31
3.1 Applications............................................................................................................................31
3.2 Safety concept.......................................................................................................................31
3.2.1 Safety components and functions..........................................................................................31
3.2.2 External safety components...................................................................................................32
3.2.3 Protection and monitoring functions of internal components.................................................32
3.2.4 Protection and monitoring functions for external components...............................................33
3.3 Design....................................................................................................................................33
3.3.1 Components...........................................................................................................................33
3.3.2 Design of the Basic Line Module............................................................................................34
3.3.3 Design of the Motor Module...................................................................................................35
3.3.4 Gating.....................................................................................................................................36
3.4 Operating principle.................................................................................................................36
3.5 Description of the components...............................................................................................36
3.5.1 SINAMICS Control Unit..........................................................................................................36
3.5.2 Terminal Modules...................................................................................................................36
3.5.3 Precharging............................................................................................................................37
3.5.4 Electromechanical door interlock system...............................................................................37
3.5.5 Make-proof grounding switch.................................................................................................38
3.5.6 Circuit-breaker (provided by the customer)............................................................................38
3.5.7 Converter transformer............................................................................................................38
3.5.8 Power Stack Adapter.............................................................................................................39
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Operating Instructions 04/2017 5

3.5.9 Actual value acquisition..........................................................................................................41
3.5.10 Common power supply..........................................................................................................41
3.5.10.1 Field of application.................................................................................................................41
3.5.10.2 Design....................................................................................................................................42
3.5.10.3 Connections...........................................................................................................................43
3.5.10.4 Interface description...............................................................................................................43
3.5.11 DM10 diagnostics module......................................................................................................44
3.5.11.1 Functions................................................................................................................................44
3.5.11.2 Measuring socket assignment................................................................................................46
3.5.11.3 Interface description of the connectors..................................................................................46
3.5.11.4 Signal processing...................................................................................................................50
3.5.11.5 Voltage monitoring.................................................................................................................51
3.5.12 Re-cooling unit ......................................................................................................................52
3.5.12.1 Re-cooling unit requirements.................................................................................................52
3.5.12.2 Operating principle of the re-cooling unit...............................................................................52
3.5.12.3 The internal deionized water circuit........................................................................................53
3.5.13 Customer terminal strips........................................................................................................53
3.6 Description of options.............................................................................................................54
3.6.1 NAMUR terminal strip (option B00)........................................................................................54
3.6.2 Auxiliary voltage supply 3 AC 200 V 50 Hz (option C30).......................................................54
3.6.3 Suitable for marine use with individual certificate from Lloyds Register (LR) (option E21)......55
3.6.4 Isolation amplifiers for optional analog inputs (option E86)....................................................55
3.6.5 Isolation amplifiers for optional analog outputs (option E87).................................................55
3.6.6 Can Bus interface (option G20)..............................................................................................56
3.6.7 Modbus Plus interface (option G21).......................................................................................56
3.6.8 Modbus RTU Slave interface (option G22)............................................................................56
3.6.9 DeviceNet interface (option G23)...........................................................................................56
3.6.10 Teleservice connection TS Adapter II analog modem (option G25)......................................56
3.6.11 Teleservice connection TS Adapter II ISDN modem (option G35).........................................56
3.6.12 1x temperature sensor evaluation unit TM150 (option G51)..................................................57
3.6.13 Additional Terminal Module TM31 (option G61)....................................................................57
3.6.14 Additional Terminal Module TM15 (option G63)....................................................................58
3.6.15 Indicator lamps in the cabinet door (option K20)....................................................................58
3.6.16 Display instruments in the cabinet door for voltage, current, speed, and output plus
indicator lamps (option K21)..................................................................................................58
3.6.17 Sensor Module SMC30 (option K50).....................................................................................59
3.6.18 Power unit with internal cooling (option K66).........................................................................59
3.6.19 Output reactor (option L08)....................................................................................................59
3.6.20 dv/dt filter (option L10)...........................................................................................................60
3.6.21 dv/dt filter (option L11)...........................................................................................................62
3.6.22 Automatic restart function (option L32)..................................................................................63
3.6.23 Line-side grounding switch (option L48)................................................................................64
3.6.24 Motor-side grounding switch (option L49)..............................................................................64
3.6.25 Cabinet illumination and service socket in closed-loop control unit (option L50)...................65
3.6.26 Disconnector at the drive output (option L51)........................................................................65
3.6.27 Circuit breaker at the drive output (option L52)......................................................................65
3.6.28 Uninterruptible power supply (UPS) (option L53)...................................................................65
3.6.29 Anti-condensation heating (option L55).................................................................................66
3.6.30 EMERGENCY STOP Category 1 (option L60)......................................................................66
3.6.31 Braking Module (option L72)..................................................................................................67
3.6.32 Safety locking system (option M10).......................................................................................67
3.6.33 Power cable connection at the drive input from above (option M13).....................................67
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3.6.34 Extended dust protection (option M16)..................................................................................68
3.6.35 Signal and control cable (max. 2.5 mm²) (option M32)..........................................................68
3.6.36 IP54 degree of protection (option M54)..................................................................................68
3.6.37 Redundant fan in the power unit (option M61).......................................................................68
3.6.38 Suitability for marine use (option M66)...................................................................................68
3.6.39 Power cable connection at the drive output from above (option M78)...................................69
3.6.40 Capacitor release (option N20)..............................................................................................69
3.6.41 Controlled outgoing circuit for auxiliary equipment 400 V 3 AC (option N30).......................70
3.6.42 Sine-wave filter (option Y15)..................................................................................................71
4 Preparations for use...................................................................................................................................73
4.1 Requirements for installation location....................................................................................73
4.2 Inspections when receiving the delivery.................................................................................73
4.2.1 Checking the delivery.............................................................................................................73
4.2.2 Scope of delivery....................................................................................................................74
4.2.3 Checking shock and tilt indicators..........................................................................................74
4.2.4 Checking the load handling attachments...............................................................................75
4.3 Transportation........................................................................................................................76
4.3.1 Transport markings................................................................................................................76
4.3.2 Transport requirements..........................................................................................................76
4.3.3 Observe center of gravity.......................................................................................................77
4.3.4 Transport with a fork-lift truck.................................................................................................77
4.3.5 Transport with a crane...........................................................................................................78
4.3.6 Using lifting rods.....................................................................................................................78
4.3.7 Transporting transportation units packed in boxes................................................................80
4.4 Unpacking..............................................................................................................................81
4.4.1 Removing the packaging........................................................................................................81
4.4.2 Removing load securing devices...........................................................................................82
4.4.3 Lifting the cabinet off the transport pallet...............................................................................82
4.4.4 Opening doors in preparation for use.....................................................................................83
4.4.4.1 Opening doors in preparation for use.....................................................................................83
4.4.5 Checking the shock and tilt indicators inside the cabinet.......................................................84
4.5 Storage...................................................................................................................................84
4.5.1 Emptying the drive.................................................................................................................84
4.5.2 Storing a device.....................................................................................................................85
5 Installation..................................................................................................................................................87
5.1 Safety instructions for assembly............................................................................................87
5.2 Tools required........................................................................................................................88
5.3 Removing transport rails........................................................................................................88
5.4 Screwing the transport units together....................................................................................88
5.5 Connecting to the foundation.................................................................................................90
5.6 Connecting cabinets...............................................................................................................90
5.7 Connecting the DC bus..........................................................................................................91
5.8 Connecting the interface terminals.........................................................................................92
5.9 Connecting the water circuits.................................................................................................93
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5.10 Removing the dust protection cover.......................................................................................94
5.10.1 Tools required........................................................................................................................94
5.10.2 Removing the dust protection cover of the closed-loop control cabinet.................................95
5.10.3 Removing the dust protection cover of the inverter cabinet...................................................96
5.10.4 Removing the dust protection cover of the rectifier cabinet...................................................97
5.11 Installing the battery of the uninterruptible power supply.......................................................99
6 Electrical connection.................................................................................................................................101
6.1 Safety instructions for electrical connections.......................................................................101
6.2 Electromagnetic compatibility...............................................................................................103
6.3 Potential concept..................................................................................................................106
6.4 Electrical requirements.........................................................................................................107
6.5 Connection...........................................................................................................................107
6.5.1 Manually unlocking power-unit doors...................................................................................107
6.5.2 Preparations for connecting the power cables.....................................................................108
6.5.3 Connecting power cables.....................................................................................................108
6.5.4 Connect the power cable to the motor and the supply system............................................109
6.5.5 Connecting ground...............................................................................................................111
6.5.6 Connect the auxiliary voltage...............................................................................................111
6.5.7 Connecting the control cables to the circuit-breaker for the capacitor release (option N20)....112
6.5.8 Connecting the encoder to the SMC30 Sensor Module.......................................................113
6.5.9 Interconnecting optional connections...................................................................................115
6.5.10 Connecting the re-cooling unit to the drive...........................................................................115
6.5.11 Fastening the cable ducts with cable ties.............................................................................116
7 Start-up ....................................................................................................................................................117
7.1 Venting the converter...........................................................................................................117
7.2 Description and configuration of the PROFIBUS interface..................................................119
7.2.1 Hardware components required for PROFIBUS communication ........................................119
7.2.2 PROFIBUS interface, diagnostics LEDs, address switches.................................................120
7.2.3 Connecting PROFIBUS cables............................................................................................122
7.2.4 Setting the PROFIBUS address switches............................................................................123
7.2.5 Requirements for communication via PROFIBUS...............................................................124
8 Operation..................................................................................................................................................125
8.1 Safety instructions for operation...........................................................................................125
8.2 Operation via the AOP30 operator panel.............................................................................126
8.2.1 General information about the AOP30 operator panel.........................................................126
8.2.1.1 AOP30 operator panel.........................................................................................................126
8.2.1.2 Buttons of the AOP30..........................................................................................................128
8.2.1.3 Basic operation of the AOP 30.............................................................................................128
8.2.2 Configuration of the AOP30 operator panel.........................................................................131
8.2.2.1 Define operation screen.......................................................................................................131
8.2.2.2 Control settings....................................................................................................................135
8.2.2.3 Inhibit functions....................................................................................................................138
8.2.3 Menu description and setting options...................................................................................141
8.2.3.1 Operation screen..................................................................................................................141
8.2.3.2 Parameterization..................................................................................................................143
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8.2.3.3 Fault/alarm memory.............................................................................................................146
8.2.3.4 Commissioning / service device commissioning..................................................................148
8.2.3.5 Commissioning / service drive commissioning.....................................................................152
8.2.3.6 Commissioning / Service - AOP settings.............................................................................153
8.2.3.7 Commissioning / Service - AOP diagnostics........................................................................157
8.2.3.8 Language.............................................................................................................................161
8.3 Parameter............................................................................................................................161
8.3.1 Parameters...........................................................................................................................161
8.3.2 Parameter types...................................................................................................................162
8.4 Functions..............................................................................................................................163
8.4.1 Setpoint channel and closed-loop control............................................................................163
8.4.1.1 Setpoint channel..................................................................................................................163
8.4.1.2 Vector control.......................................................................................................................166
8.4.1.3 U/f control.............................................................................................................................169
8.4.2 Analog and digital inputs/outputs.........................................................................................170
8.4.2.1 Analog outputs.....................................................................................................................170
8.4.2.2 Digital outputs......................................................................................................................173
8.4.2.3 Digital inputs/outputs............................................................................................................174
8.4.2.4 Additional settings for analog outputs..................................................................................175
8.4.2.5 Scaling the input signal of the analog inputs........................................................................178
8.4.3 Monitoring functions and protective functions......................................................................179
8.4.3.1 Insulation monitoring............................................................................................................179
8.4.3.2 Tripping of the circuit-breaker in case of undervoltage........................................................180
8.4.3.3 DC-link short-circuiter...........................................................................................................180
8.4.3.4 Vdc-max closed-loop control................................................................................................181
8.4.3.5 Fan monitoring.....................................................................................................................183
8.4.3.6 Speed monitoring with incremental encoder........................................................................183
8.4.3.7 Controlled stop, EMERGENCY STOP category 1...............................................................183
8.5 Fault and system messages................................................................................................184
8.5.1 External alarms and faults....................................................................................................184
8.5.2 Message from the grounding switch....................................................................................184
8.5.3 Diagnosis.............................................................................................................................185
8.5.3.1 Indicating and rectifying faults..............................................................................................185
8.5.3.2 Diagnostics via LEDs...........................................................................................................186
8.5.3.3 Diagnostics via parameters..................................................................................................187
9 Maintenance.............................................................................................................................................193
9.1 Safety instructions for maintenance.....................................................................................193
9.1.1 High snubber circuit capacitor voltages...............................................................................193
9.2 Grounding the system..........................................................................................................196
9.2.1 Grounding with a grounding device......................................................................................196
9.2.2 Grounding using a make-proof grounding switch.................................................................198
9.3 Opening the doors................................................................................................................198
9.3.1 Opening the power unit doors for maintenance work...........................................................199
9.3.2 Manually unlocking power unit doors...................................................................................199
9.3.3 Secure locking system (option M10)....................................................................................200
9.4 Preventive maintenance.......................................................................................................201
9.4.1 Inspection.............................................................................................................................201
9.4.2 Checklist for preventive maintenance work..........................................................................201
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9.4.3 Visual inspections................................................................................................................202
9.4.3.1 Equipment for visual inspections..........................................................................................202
9.4.3.2 Checking the isolating clearances........................................................................................203
9.4.3.3 Checking hoisting solenoids and security bolts....................................................................203
9.4.3.4 Checking the plug connections............................................................................................203
9.4.3.5 Checking the cable and screw terminals..............................................................................203
9.4.3.6 Checking the capacitor release (option N20).......................................................................203
9.5 Maintenance.........................................................................................................................204
9.5.1 Fan maintenance.................................................................................................................204
9.5.1.1 Replacing the fan (option L08).............................................................................................204
9.5.2 Replacing the back-up battery of the AOP30 operator panel ..............................................205
9.5.3 Load operator panel firmware, parameter and signal descriptions......................................207
9.6 Cleaning...............................................................................................................................208
9.6.1 Removing dust deposits.......................................................................................................208
9.6.2 Cleaning aluminum parts.....................................................................................................208
9.7 Repairs.................................................................................................................................209
9.7.1 Torques................................................................................................................................210
9.7.2 Replacing the diode module.................................................................................................211
9.7.3 Replacing the PowerCard....................................................................................................214
9.7.4 Replacing the operator panel...............................................................................................218
9.7.5 Replacing the CompactFlash card.......................................................................................219
9.7.6 Replacing the precharging transformer................................................................................219
9.7.7 Replacing the precharging rectifier......................................................................................221
9.7.8 Replacing the AVT combination module..............................................................................222
9.7.9 Replacing fuses....................................................................................................................223
9.7.10 Replace the sponge for the leak detector............................................................................223
9.7.11 Replacing the Power Stack Adapter....................................................................................224
10 Spare parts...............................................................................................................................................227
11 Disposal....................................................................................................................................................229
11.1 Disposing of packaging material..........................................................................................229
11.2 Removing device components and old devices...................................................................229
A Service & Support.....................................................................................................................................231
B Technical data and drawings....................................................................................................................233
B.1 Technical specifications.......................................................................................................233
B.1.1 Notes about technical specifications....................................................................................233
B.1.2 Standards and regulations...................................................................................................233
B.1.3 Series connection variant of Basic Line Modules (option N15)............................................234
B.1.4 Connection variant: 24-pulse supply with series connection of two Basic Line Modules
(option N15, Y15).................................................................................................................234
B.1.5 General technical specifications of the drive........................................................................234
B.1.6 Technical specifications of the common power supply........................................................237
B.1.7 Technical specifications of the diagnostics module DM10...................................................238
B.2 Terminal assignments..........................................................................................................238
B.2.1 Control pulpit interface (Terminal Modules TM31 and TM15)..............................................238
B.2.2 Terminal assignment of the NAMUR terminal strip (option B00).........................................239
B.2.3 Circuit-breaker interface.......................................................................................................240
B.2.4 Interfaces of the Power Stack Adapter.................................................................................241
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B.2.4.1 Gating of the power semiconductors....................................................................................241
B.2.4.2 Selecting Safe Torque Off....................................................................................................241
B.2.4.3 Actual value channels..........................................................................................................242
B.2.4.4 Trip line................................................................................................................................242
B.2.4.5 DRIVE-CLiQ interface..........................................................................................................242
B.2.4.6 Analog and digital outputs....................................................................................................243
B.2.4.7 Switch for the analog inputs.................................................................................................243
B.2.4.8 Analog and digital inputs and temperature sensor connections...........................................244
B.2.4.9 Electronics power supply.....................................................................................................245
C Checklists and forms................................................................................................................................247
C.1 Mechanical installation: Checklist........................................................................................247
C.2 Checklist for electrical installation........................................................................................248
Index.........................................................................................................................................................253
Tables
Table 3-1 Connector -X231.........................................................................................................................47
Table 3-2 Connector -X232.........................................................................................................................48
Table 3-3 Connectors -X1 and -X31............................................................................................................48
Table 3-4 Connector -X32...........................................................................................................................49
Table 3-5 Connector -X33...........................................................................................................................49
Table 3-6 Connector -X34...........................................................................................................................49
Table 3-7 Connector -X35...........................................................................................................................49
Table 3-8 Connector -X36...........................................................................................................................50
Table 3-9 Deionized water requirements.....................................................................................................53
Table 3-10 Braking power Braking Module with external brake resistor.......................................................67
Table 3-11 Max. permissible cable lengths...................................................................................................71
Table 6-1 Dimensioning cables.................................................................................................................107
Table 6-2 Cable cross-sections.................................................................................................................107
Table 6-3 Drive and motor connection terminals.......................................................................................110
Table 7-1 PROFIBUS interface X126........................................................................................................121
Table 7-2 Description of the DP1 LEDs.....................................................................................................121
Table 8-1 List of signals for the operation screen......................................................................................134
Table 8-2 Scaling.......................................................................................................................................135
Table 8-3 Overview of important parameters (equipment commissioning)...............................................150
Table 8-4 Drive Object VectorMV..............................................................................................................152
Table 8-5 Parameter..................................................................................................................................164
Table 8-6 Parameter..................................................................................................................................164
Table 8-7 Parameter..................................................................................................................................165
Table 8-8 Parameter..................................................................................................................................166
Table 8-9 LEDs of the Power Stack Adapters ..........................................................................................186
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Table 8-10 LEDs of the DM10 diagnostics module.....................................................................................187
Table 9-1 Technical specifications of the backup battery..........................................................................205
Table 9-2 Tightening torque for screws.....................................................................................................210
Table 9-3 Tightening torques for screw terminals for copper cables without cable lug 1)..........................210
Table 9-4 Torques.....................................................................................................................................213
Table B-1 Standards and conformity.........................................................................................................233
Table B-2 General technical specifications................................................................................................234
Table B-3 Cooling......................................................................................................................................235
Table B-4 Closed-loop control related properties......................................................................................236
Table B-5 Climatic environmental conditions.............................................................................................236
Table B-6 Mechanical ambient conditions.................................................................................................237
Table B-7 Other ambient conditions..........................................................................................................237
Table B-8 Technical specifications of the common power supply.............................................................237
Table B-9 Technical specifications of the AD586LR reference element....................................................238
Table B-10 Terminal assignment of customer interface TM15....................................................................238
Table B-11 Terminal assignment of customer interface TM31....................................................................239
Table B-12 Terminal assignment of NAMUR terminal strip.........................................................................239
Table B-13 Terminal assignment for circuit-breaker interface .LA -X11......................................................240
Table B-14 Terminal assignment for circuit-breaker interface .LA -X52 with OFF and undervoltage coil....240
Table B-15 Terminal assignment for circuit-breaker interface .LA -X52 with two OFF coils and
undervoltage coil.......................................................................................................................240
Table B-16 Terminal assignment for circuit-breaker interface .LA -X52 with capacitor release..................240
Table B-17 Power Stack Adapter 2: Actual value channels.........................................................................242
Table B-18 Power Stack Adapter 2: Trip line...............................................................................................242
Table B-19 DRIVE-CLiQ interface...............................................................................................................242
Table B-20 Power Stack Adapter 2: Analog and digital outputs..................................................................243
Table B-21 Power Stack Adapter 2: Switch for the analog inputs...............................................................243
Table B-22 Power Stack Adapter 2: Analog and digital inputs and temperature sensor connections.........244
Table B-23 Power Stack Adapter 2: Electronics power supply....................................................................245
Figures
Figure 3-1 Design of the power unit..............................................................................................................34
Figure 3-2 Basic Line Module with diodes in 12-pulse configuration............................................................35
Figure 3-3 Motor Module..............................................................................................................................35
Figure 3-4 Overview of PSA interfaces.........................................................................................................40
Figure 3-5 AVT combination module............................................................................................................41
Figure 3-6 Design when using IGBTs...........................................................................................................42
Figure 3-7 Overview ....................................................................................................................................43
Figure 3-8 Logical design of the DM10 diagnosis module............................................................................45
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Figure 3-9 Printed circuit board of the diagnostics module...........................................................................46
Figure 3-10 Circuit diagram option L10..........................................................................................................60
Figure 3-11 Connecting the motor to the dv/dt filter.......................................................................................61
Figure 3-12 Circuit diagram option L11..........................................................................................................62
Figure 3-13 Connecting the motor to the sine-wave filter...............................................................................71
Figure 4-1 Example of attaching and displaying the shock and tilt indicators..............................................75
Figure 4-2 Example illustration of centers of gravity.....................................................................................77
Figure 4-3 Lifting bar label............................................................................................................................79
Figure 4-4 Securing the lifting rods...............................................................................................................80
Figure 4-5 Transporting a transportation unit (still in packaging) with a crane.............................................81
Figure 4-6 Example: Label with instructions for opening the doors..............................................................83
Figure 4-7 Example: Cover screw for manual door interlocking...................................................................83
Figure 5-1 Removing the support rails..........................................................................................................88
Figure 5-2 Screwing cabinets together.........................................................................................................89
Figure 5-3 Grounding bar.............................................................................................................................91
Figure 5-4 DC-bus connection......................................................................................................................92
Figure 5-5 Assembling the DC-bus connection............................................................................................92
Figure 5-6 Example: Connecting interface terminals ...................................................................................93
Figure 5-7 Dust protection cover, closed-loop control cabinet......................................................................95
Figure 5-8 Dust protection cover, inverter cabinet........................................................................................96
Figure 5-9 Dust protection cover, rectifier.....................................................................................................98
Figure 5-10 Remove the screws.....................................................................................................................99
Figure 5-11 Install battery.............................................................................................................................100
Figure 6-1 Shield connection using a clip...................................................................................................105
Figure 6-2 Bridging shield gaps..................................................................................................................105
Figure 6-3 Potential concept.......................................................................................................................106
Figure 6-4 Example: Connecting the power cables....................................................................................108
Figure 6-5 Connection of the supply-system power cable..........................................................................110
Figure 6-6 Grounding lug............................................................................................................................111
Figure 6-7 Connection for auxiliary voltages..............................................................................................112
Figure 6-8 Connecting the external encoder to the SMC30 Sensor Module..............................................114
Figure 6-9 Connection example 1: HTL encoder, bipolar, with reference signal........................................115
Figure 6-10 Schematic diagram: Fastening the cable ties............................................................................116
Figure 7-1 Example: Venting valve.............................................................................................................118
Figure 7-2 Open the vent valve..................................................................................................................119
Figure 7-3 Example: Air pocket..................................................................................................................119
Figure 7-4 PROFIBUS interface.................................................................................................................120
Figure 7-5 X126 PROFIBUS connection....................................................................................................120
Figure 7-6 PROFIBUS address switch cover.............................................................................................122
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Figure 7-7 PROFIBUS connectors.............................................................................................................122
Figure 7-8 Position of the bus terminating resistors...................................................................................123
Figure 8-1 AOP30 operator panel...............................................................................................................127
Figure 8-2 Menu structure of the AOP 30...................................................................................................129
Figure 8-3 Function keys of the AOP 30.....................................................................................................130
Figure 8-4 Example of the operation screen...............................................................................................131
Figure 8-5 Menu structure of the operation screens...................................................................................141
Figure 8-6 Parameterization menu structure..............................................................................................143
Figure 8-7 Selecting data sets....................................................................................................................145
Figure 8-8 Menu structure for fault memory/alarm memory.......................................................................146
Figure 8-9 Alarm screen.............................................................................................................................148
Figure 8-10 Commissioning / service / device commissioning menu structure............................................148
Figure 8-11 Commissioning / service / drive commissioning menu structure...............................................152
Figure 8-12 Commissioning /Service / AOP settings menu structure...........................................................153
Figure 8-13 Commissioning / Service / AOP diagnostics menu structure....................................................157
Figure 8-14 Language menu structure.........................................................................................................161
Figure 8-15 Parameter types........................................................................................................................162
Figure 8-16 Switchover conditions................................................................................................................168
Figure 8-17 Operating areas and characteristic curves for the induction motor with drive supply...............169
Figure 8-18 Example: Setting analog output 0.............................................................................................172
Figure 8-19 Potential supply of external signals...........................................................................................174
Figure 8-20 Digital signal output to the system I/O.......................................................................................175
Figure 9-1 Grounding points.......................................................................................................................197
Figure 9-2 Attaching the grounding spider..................................................................................................197
Figure 9-3 Make-proof-grounding switch closed.........................................................................................198
Figure 9-4 Principle of the mechanical door interlock.................................................................................200
Figure 9-5 Components of the secure locking system................................................................................200
Figure 9-6 Fan removal .............................................................................................................................204
Figure 9-7 Replacing the backup battery....................................................................................................206
Figure 9-8 Release the screw connection of the line supply connection busbar........................................212
Figure 9-9 Release the screw connection of the DC link busbar................................................................212
Figure 9-10 Removing the retainers for the water hoses..............................................................................213
Figure 9-11 Releasing screw connections....................................................................................................215
Figure 9-12 Removing the PowerCard: Remove the retainers for the water connections............................216
Figure 9-13 Replacing the operator panel....................................................................................................218
Figure 9-14 Replacing the precharging transformer.....................................................................................220
Figure 9-15 Replacing the precharging rectifier............................................................................................221
Figure 9-16 Example of an AVT combination module..................................................................................222
Figure 9-17 Sponge......................................................................................................................................223
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Figure 9-18 Replacing the sponge................................................................................................................224
Figure B-1 24-pulse supply via series connection of two Basic Line Modules; option N15........................234
Figure B-2 24-pulse supply via series connection of two Basic Line Modules (option N15), with
sinusoidal filter for operating line motors (option Y15)..............................................................234
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Introduction 1
1.1 About these instructions
These instructions describe the drive and explain how to handle it, from initial delivery to final
disposal of the equipment. Keep these instructions for later use.
Read these instructions before you handle the drive and follow the instructions. The
instructions contain information about the safe handling of the drive as well as its components
and modules. They provide information on assembling, installing, and maintaining the
equipment properly.
If you have suggestions for improving the document, please contact our Service Center
(Page 231).
Text format features
The warning notice system is explained on the rear of the inside front. Always follow the safety
instructions and notices in these instructions.
In addition to the safety-related warning notices which you must read, you will find the text in
these instructions is formatted in the following way:
1. Handling instructions are always formatted as a numbered list. Always perform the steps
in the order given.
● Lists are formatted as bulleted lists.
– Lists on the second level are hyphenated.
Note
A Note is an important item of information about the product, handling of the product or the
relevant section of the document. Notes provide you with help or further suggestions/ideas.
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Introduction
1.1 About these instructions
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Safety instructions 2
In the individual chapters of this document, you will find safety instructions that must be obeyed
absolutely, for your own safety, to protect other people and to avoid damage to property. Pay
attention to the following safety instructions for all activities on the inverter.
2.1 Warning symbol on the device
Please observe the warning symbols attached to the device. The warning symbols have the
following meaning:
Warning symbol Meaning
Warning: Voltage
Warning: Hot surface
General warning symbol: Observe the explanations about the hazard on the
device labels.
For transportation, observe the "transportation markings (Page 76)" on the device packaging.
2.2 Qualified personnel
The product/system described in this documentation may only be operated by personnel
qualified for the specific task in accordance with the relevant documentation for the specific
task, in particular its warning notices and safety instructions. Because of their training and
experience, qualified personnel can recognize any risks involved with handling these products/
systems and avoid any possible dangers.
2.3 The five safety rules
For your own personal safety and to prevent material damage when carrying out any work,
always observe the safety-relevant instructions and the following five safety rules according
to EN 50110‑1 "Working in a voltage-free state". Apply the five safety rules in the sequence
stated before starting work.
Five safety rules
1. Disconnect the system.
Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
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3. Verify absence of operating voltage.
4. Ground and short-circuit.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.
2.4 Safe handling
WARNING
High voltages from external supplies
Even if the circuit breaker is open, parts of the drive can be under voltage (live) as a result of
the auxiliary voltage at the premagnetization, precharging or demagnetization transformers.
This danger is not limited to the drive, but can also occur with components that are electrically
connected to the drive (e.g. circuit breakers or isolators). Touching live parts can result in
death, serious injury, and damage to property.
● Isolate all components that can feed voltage to the converter before commencing work.
WARNING
High voltages during operation
When operating this equipment very high voltages develop. Even after switching off the mains
voltage, or while the connected machine is still turning, high voltages can remain for a
prolonged length of time. High voltages can cause death or serious injury if the safety rules
are not observed or if the equipment is handled incorrectly.
● Operate the drive properly.
● Always follow the "The five safety rules (Page 19)" when performing any work.
● Only remove the covers using the methods described by these operating instructions.
● Maintain the drive regularly and correctly.
WARNING
High voltages from machines still turning and connected
Rotating machinery can induce dangerous high voltages and synchronous motors that are
not de-excited immediately can also pose a hazard. If the connection to the motor is not
isolated or grounded, these voltages can also remain. Touching live parts can result in death
or serious injury.
● Before opening the doors, wait until the connected machine has come to a standstill.
Safety instructions
2.4 Safe handling
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